Chapter 1.

0: Introduction

1.1 Application of research

Power factor is the ratio between the KW and the KVA drawn by an electrical load where the KW is the actual load power and the KVA is the apparent load power. It is a measure of how effectively the current is being converted into useful work output and more particularly is a good indicator of the effect of the load current on the efficiency of the supply system.

When an electric load has a PF. lower than 1, the apparent power delivered to the load is greater than the real power that the load consumes. Only the real power is capable of doing work, but the apparent power determines the amount of current that flows into the load, for a given load voltage.

All current will causes losses in the supply and distribution system. A load with a power factor of 1.0 provides most efficient loading of the supply and a load with a power factor of 0.5 will result in much higher losses in the supply system. A poor power factor can be the result of a significant phase difference between the voltage and current at the load terminals. Poor load current phase angle is generally the result of an inductive load such as an induction motor, power transformer, lighting ballasts, welder or induction furnace.

1.2 Objective of this thesis

An improved power factor AC output is the main target of this project. This project focuses on the design and implementation of power factor correction using PIC microcontroller chip, determine the power factor of the loaded power system, generate proper action to calculate and to pin point adequate capacitor to redeem appropriate power lost under the project design using MikroC program and finally test or simulate the design with PIC chip stand individual without interface of personal computer.

1.3 Structure of thesis

This thesis is divided into main six chapters that are literature background, role of capacitor, different approach of power factor correction, System Design,

implementation & results, future direction and conclusion. The literature background (chapter 2) discuss about the fundamentals knowledge of power factor and its applications. While the role of capacitor (chapter 3) is one main component that used to correct power factor, its relation with power factor and application background are mainly explain in this chapter.

In meantime, few types of power factor correction methodologies under difference circumstances are outlined for the present power factor correction methods used in various approaches (chapter 4). Then next chapter (chapter 5) is the system design of this project; this section explains the process of how the overall design works using PIC micro-controller chip. After the explanation of the working principle of the system design, the testing results and ways of implementation will be analyzed and discussed in

chapter 6. Finally, in chapter 7, this thesis ends with conclusion as well as recommendations for future research.

Chapter 2.0: Literature Background

2.1 Power Relation with power factor

It is known that reactive loads such as inductors and capacitors dissipate zero power, yet the fact that they drop voltage and draw current gives the deceptive impression that they actually do dissipate power. This "phantom power" is called reactive power, and it is measured in a unit called Volt-Amps-Reactive (VAR), rather than watts. The mathematical symbol for reactive power is the capital letter Q. The actual amount of power being used, or dissipated, in a circuit is called true power, and it is measured in watts (symbolized by the capital letter P). The combination of reactive power and true power is called apparent power, and it is the product of a circuit's voltage and current, without reference to phase angle. Apparent power is measured in the unit of Volt-Amps (VA) and is symbolized by the capital letter S.

There are several power equations relating the three types of power to resistance, reactance, and impedance (all using scalar quantities), E here refers as voltage in singlephase:

P = EI cos

(real part) (imaginary part)

Q = EI sin

S = EI = P 2 + Q 2 = P + jQ
PF = P EI cos Q = = cos = cos tan 1 S EI P

Where, P = Real Power (unit in Watt), Q = Reactive Power (unit in VAR) and S = Apparent power (unit in VA) PF = power factor

For three-phase system, the power equation mostly measure in kilo-unit or Mega-unit, where ph denotes as phase and L denotes as line. Before attempting to determine the power factor in three-phase system, there are mainly two ways of loads connection appears in three-phase power system: wye (or star) connection and delta connection, that needs to be aware of. (H. Saadat, 1999)

In wye-connection load, (Y)

VL = 3 VPh 30 I L = I ph

As for in delta connection, ()

VL = V ph I L = 3 I ph 30

And the relationship of wye and delta connection in impedance is as follow.

ZY =

Z 3

Thus the power relationship would be

Pph =

3 j=N 3 j=N V Lj I * with cos ; V pj I * or PL = pj Lj N j =1 N j =1

Q=

3 N

(V
N j =1

pj

I * pj or Q =
1

3 VLj I pj with sin ; N

1 S = 3 N

(V )
N j =1 pj N

1 N
1 2

(I )
N j =1 pj N

or
1

1 S = 3 N PF =

(V )
j =1 Lj

1 N

(I )
j =1 pj

Q (kVAR) P kW = = cos = cos tan 1 S kVA P (kW )

The power equations shown in previous section are in balanced condition. Apparently, a pure balanced condition is rarely existed but mostly able to draw near to acceptable range. One of the main reason the results to unbalance are earthed system elements that leads to current flowing in earthed neutral and earth ground itself is a gigantic grounding terminal that easily create faulty for electronic circuit if without proper prevention and taking safety caution.

The equations for unbalanced condition use a, b and c for different loads notation; in other words, instantaneous power is formed by summation of instantaneous values of Va, Vb, and Vc multiply with of instantaneous values of current Ia, Ib and Ic.

P = Va I a + Vb I b + Vc I c
Where, I a + I b + I c = 0

Therefore the power expression would be,

Using I C = (I a + I b )

P = Va I a + Vb I b + Vc (I a + I b )
Or

P = (Va Vc ) I a + (Vb Vc ) I b

On using Vac = Va Vc and Vbc = Vb Vc

P = Vac I a + Vbc I b

Therefore with respect of time-series, the expression of real power and reactive power is as shown below.

1 j=N P = Re Vacj I * + Vbcj I * aj bj N j =1

1 j=N Q = Im Vacj I aj + Vbcj I bj N j =1

The apparent power and the power factor calculation would be the same as balanced condition.

2.2 Why power factor correction

As slight explained in the introduction, the existing of reactive power does not included in the electric bill yet this probably causes dissipation power lost at the load, which results to an increment of electricity bill charge. Penalty charge is just one of the feature concerned mostly by electricity user, however there are more other problem occurs if power factor is low.

Penalty charge in electric bill; Extra losses in feeder cables; Significant voltage drop reduction of effective capacity of cables Reduction in power available at the transformer Significant voltage drop at the secondary of the transformer Significant losses in transformer

2.2.1 Reasons cause lower power factor

All current will causes losses in the supply and distribution system. A load with a power factor of 1.0 results in the most efficient loading of the supply and a load with a power factor of 0.5 will result in much higher losses in the supply system. A poor power factor can be the result of either a significant phase difference between the voltage and current at the load terminals, or it can be due to a high harmonic content or distorted/discontinuous current waveform. System that has inductors like motors and electronic devices will produce inductive reactance and thus generate lagging reactive power. The main reason is the current 8

flows within power system. No matter how a power system designed, current will surely causes loss in both supply and distributed loads. Load with power factor of 1.0 has best efficient of power usage upon the load itself and this can only appear in pure resistive circuit. A poor power factor appears due to the significant phase difference between voltages and currents at load terminals are large, which thus gives power factor value lower than unity (=1).

Unfortunately this is not the only reason that power factor drop. High harmonic or distorted/discontinuous current waveform will also cause low power factor; however this is not mainly designed but it will be discussed in chapter 4, which about various approaches attempt to different kind of power factor failures. System that contains motor, power transformer, lighting ballasts, welder or induction furnace are the main reasons that result phase shift in sinusoidal load current. While system that possess rectifier, variable speed drive, switched mode power supply, discharge lighting or other electronic load creates harmonics and have high possibility cause current signal to be distorted or discreet. Simple capacitor bank cannot fix the such problem, a change in equipment design or expensive harmonic filters are needed to perform further improvement.

2.3 Power factor correction Process

This can be discussed with an example [quote]. Since single-phase is considered one of the phase in three-phase system when connected in wye-connection, hence the following calculation procedures would use single-phase scene as base.

I I1 I2 10 200V 100 j20

IC

2000 = 20 A 100 2000 I2 = = 4 j8 A 10 + j 20 I1 = S1 = VI 1 = 2000 (2 j 0 ) = 400W + j 0 var

S 2 = VI 2 = 2000 (4 + j8) = 800W + j1600 var

Total apparent power and current are

S = P + jQ = 1200 + j1600 = 200053.13 VA I= S 2000 53.13 = = 10 53.13 A 2000 V

The power factor vat the source is

PF = cos(53.13) = 0.6 lagging

The main target is to get nearer power factor to unity hence the following action being done.

10

Total real power remains the same, P = 1200 W with new power factor choose to be cross to unity, say 0.95 lagging

new = cos 1 (0.95) = 18.19

Qnew = P tan new = 1200 tan (18.19) = 394.4 var QC = 1600 394.4 = 1205.6 var ZC = V SC
2

(200)2
j1205.6

= j 33.18

C=

1 = 95.93F 2 50 33.18

Since there is no exactly 95.93F, a near capacitor value like 90F can be chosen with a slight lower of PF value.

This example pre-determined a desired power factor of 0.95 so getting a nearest PF can also choose capacitor value of 100F with PF value is approximately 0.96 (or 96%) but if a system designed to get as close to unity, it is better to pick a lower capacitor value to avoid excessive of leading current flow into the line bus. Since unity power factor gives rise to the greatest utilization of the plant. Electric utilities measure reactive power used by high demand customers and charge higher rates accordingly.

11

Chapter 3.0: Role of Capacitor

Frequency is standardized at constant 50 Hz, or 60 Hz in other countries; power factor correction is veiled as a solution to such fixed network frequency, the only key solution is by addition of capacitor in shunt to the load. Capacitors are commonly used within a lot of power system, especially electronic constructed circuitry. Though common it is, it is consequently least understood by majority as one most beneficial component for power system.

Release of system capacity Reduction of kVAR generation requirements Reduction of system loss Regulation or improvement in voltage

These benefits require only small amount of investment and maintenance compare to a lot of power system components. Budgeting expenses itself already a solid reason for why capacitors are most welcome in many power system.

In three-phase power system, capacitors normally installed within an isolating nonconductor metal box, which called capacitor bank; they are either fixed or switched. Fixed banks are connected permanently to the primary conductors through fused switches. Switched banks are tied to the primary system through automated switches, allowing them to be put on line and taken off line as needed. Distribution power system usually connects capacitor in parallel (also called shunt) rather connecting in series. 12

The function of shunt power capacitor is to provide leading (capacitive) kVARs to an electrical system when and where needed. Lagging (inductive) kVARs appear when there are inductors (coils) exist within electrical (e.g. motor) or electronic (personal computer) equipments, as the amount grows, the increment of inductive kVARs will increase as well, thus the demand of capacitive kVARs to compensate is pretty much required in order to reduce unnecessary lost. (TVPPA, Distribution Design Guideline)

The actual capacitor in farads of a capacitor bank can be calculated using the following equation:

C=

VAR 2f VR
2

(3-1)

where, VAR = capacitor unit VAR rating C f VR = capacitor (farads) = frequency (cycles/second) = capacitor unit rated voltage

3.1 Relationship of capacitor with power factor

Capacitor is the main component that supplies capacitive reactance, which is negative reactive power. Since the power factor is the ratio of real power and apparent power, where apparent power has the relation with reactive power and real power as shown in the power triangle in figure 3-1. As majority power system has inductive loads thus normally only lagging power factor occurs hence capacitors are used to compensate by

13

producing leading current to the load to reduce the lagging current, thereby shrink the phase angle distance between the real power and apparent power.

Figure 3-1: Power triangle

Table 3-1 list a number of common loads appears in general industrial systems and their typical power factor.

Load Typical Power Factor Incandescent lamps 1.0 Florescent lamps 0.95 0.97 Synchronous motors 1.0 to 0.80 leading Squirrel cage motors High speed 0.75 0.90 Low speed 0.85 0.92 Wound rotor 0.80 0.90 Induction motors Fractional HP 0.55 0.75 1 10 HP 0.75 0.85 Arc furnace 0.65 0.70 Power Converter 0.50 0.90
Table 3-1: Typical power factors of end use equipment

3.1.1 Connection Type

In general, power capacitors shall be wye-connected on the three-phase distribution feeder. Grounding the neutral is essential for the fuses to operate in case of any event of capacitor fault. For a small ungrounded wye-connected capacitor bank, faulty capacitor

14

would not blow the fuse to isolate faulty capacitor. Any event of this could lead to an explosion to the capacitor bank.

However, Isolating the neutral of the wye of a capacitor bank has the advantage of reducing harmonics. (Quote) The method can only be an alternative when grounding the neutral would cause operating difficulty for a particular installation. In case of insulation failure inside the unit, phase-to-ground fault can still occurs to an ungrounded wye capacitor bank even with its enclosure properly grounded.

The most effective solution is to insert reactors in series with each capacitor group connected between the phase wire and the neutral of a three-phase bank. This method is used to mitigate any resonant circuit, while reduction of induction triple harmonic frequency current can be made.

3.2 Determine Size of Capacitor Banks

Standard capacitor sizes are 50, 100, 150, 200, 300 and 400 kVAR. Since three-phase installations are pretty much the same as single phase installation, which single-phase is just one of the phase among three phase connection. Of course, the formula for both phases will be different. Since capacitors can be connected more than one per phase in order to increase the bank size, it is recommended to select two or at most three capacitor unit sizes to avoid stocking the sizes. (TVPPA Group, Distribution design Guidelines)

15

ILAG MAX ILAG Loss reduction = 0% Time

Rective current without capacitor

ILAG MAX

Cap off at ILead Max = (2/3)Icap Loss reduction = 89% Icap

Cap off at ILead Max = (1/3)Icap

Reactive current with capacitor (Maximum loss reduction)

Figure 3-2: Reactive current with capacitor (maximum loss reduction)

(TVPPA, Distribute design guidelines)

How much amount of capacitance to install within a bank is considered sufficient? In a fixed capacitor installation, one should at first determine desired power factor value before attempting to design one. By installing fixed capacitor can approximately improve the power factor around 94% to 96%. Higher power factor may only be acquired with switched capacitor banks.

When using switched capacitor to correct the power factor of a circuit, the switch control is set to close the bank onto the line when the load kVARs equal two-thirds of the banks rated kVAR. This scheme is tend to reduce loss by driving the line leading

16

with first turn on before it is turn off, this is referred as the two-thirds rule. Taking a daily load cycle as shown in figure 3-2 as example.

Compare with fixed capacitor bank, switching capacitor bank is generally more expensive thus it is essential to take accounting of the cost of installation so that its time value worth for the investment.

3.3 Possible Problems Occur in Capacitor Bank

Despite the benefits provided by capacitor bank, there are several possible undesired events occur in the process of using capacitor bank, which mostly happen when capacitor performs charge and discharge process.

3.3.1 Switching Counter Strike

In three-phase bank of capacitor connected in wye with neutral grounded, the initial voltage is practically zero since capacitor on load side of the switch holds the same instantaneous voltage as existed on the supply side. Since capacitive current leads voltage by 90, voltage of capacitor peak and circuit at same value, voltage across the switch contacts tend to be twice the peak value compare with the fundamental on half cycle period which capacitor at its moment of full charged and the supply voltage in meantime reached its peak of opposite value, as shown in figure

17

Capacitor Voltage

To =
Beginning of switching opening; 2EC across switch contacts

T1 = First
current zero;

T2 = cycle
after first current zero;

Voltage

T3 = switch
completely opened.

T0

T1

T2 T3

Current
Figure 3-3: Voltage across switch contacts during the first half cycle.

(TVPPA, Distribution Design Circuit) For the moment across switch gap, the capacitor voltage will overshoot when attempted change in voltage in order voltage across the capacitor interrupted leaving three times its steady state value. Same behavior happens in first current zero as its arc again may be interrupted leaving three times normal peak voltage on the capacitor. After one-half cycle, another four times will appear at switch contact as shown in figure 3-4. These two time periods of overshoot behaviors are the counter striking back to the circuit, therefore sufficiently separation between contacts or else a counter strike across switch gaps will occurs. Proper steps like choice of switching devices and component like diode that only allow one way current flow to protect controlling circuit from counter striking.

18

Bus voltage

4 EC switch contacts after counter strike

Voltage

Counter Strike

C
Figure 3-4: A strike caused by difference of capacitor voltage and line voltage.

(TVPPA, Distribution Design Guideline)

3.3.2 Harmonic Problem

Increment of power electronic devices had drawn attention of high concern with harmonics level. Capacitors individual does not cause harmonic current; however, the rising of frequency when capacitive impedance drop will results harmonics generation and affecting the magnitude of voltages and currents within the buses, especially when capacitor banks connected in grounded wye to earth.

It is advised that capacitor bank should be placed at somewhere with proper distance based on pre-defined desire power factor, rated voltage, etc with the actual system. Another method is use ungrounded wye connection, this will prevent harmonic

19

produces but careful study of capacitor switches to prevent switching counter attack and capacitor bank short circuit protection.

For small capacitor bank, connecting in delta formation also have the same effect but make sure proper discharge function must be installed, like connecting resistors in between line-to-line of the three-phase delta-connected capacitor; nevertheless, the switching effect problem must still be cautioned.

20

Chapter 4.0: Different Approaches of PFC

In the precious chapter, the method that directly used of capacitor to correct power factor as discussed in section 2.3 only applicable when current waveform was nearly perfect sine wave. There are nowadays many power systems contains complicated power electronic components or drives systems, such as converters, inverters, variable drives system, etc; these types of power systems would mostly distort current waveform or produce discreet signal output. Therefore this chapter will briefly converse about different type of approaches apply in power factor correction for various type of electrical power systems.

This chapter mainly categorized into two major types of power factor collecting circuit methodologies. The first category is called the passive power factor correction, which usually more reliable, inexpensive and typically improves power factor value up to a maximum of 80%; while the second category that generally more effective and able to achieve over 95% of corrected power factor is called the active power factor correction method, this types generally integrated with switch-mode power supply. (Power factor, LM Photonics Ltd.)

4.1 Passive PFC

Passive power factor correction is quite common in many distribution power system, it mainly use capacitive filter (or fixed capacitors) to generate leading reactive current to correct poor power factor. The initial setting of the AC input voltage will determine the

21

amount of capacitive filter needed for the power system and all this being done manually. This type of power factor correction is practically sufficient enough for system that had planned not to be altered much at the input for long time; and certainly it is comparatively cheap compare to active PFC, which would be discussed in section 4.2. Generally, the desired power factor value is pre-calculated and selects sufficient capacitors to perform constant power factor correction. However, passive PFC may be affected when environmental vibration occurs and it cannot fully utilise the energy potential of the AC line. [1]

Certainly that passive PFC can only apply to general power system that acquires pure sinusoidal voltage and current waveforms. For sophisticate power electronic systems that easily affected by harmonic distortion, active PFC is a better choice for long term investment.

4.2 Active PFC

Active power factor is more preferable since it capable in providing more efficient power frequency by diminishing total harmonics and phase different in between input current and input voltage. Majority of active power factor are circuits built integrate with the switched mode power supply, using IC and other active elements like diode and FET. Follow ahead of this sector are introduction of few types of active PFC.

The effect of harmonic distortion makes many advanced systems suffer with lower power factor as by normal mean of power factor correction method cannot solve the problem as current might not even have the shape of sine wave. A diagram in figure 4-1

22

shows what exactly happen to the distorted current compares with perfect sinusoidal current waveform.

Figure 4-1: Voltage and current waveform behavior

I represents the fundamental current out of phase in sine wave in an angle difference, ; while I is the actual current waveform. In other word, passive PFC circuit only capable to correct poor power factor when only I exist in the power system, but if instead I occur then the corrected power factor using passive PFC circuit would not be precise; losses and weak performance still remain yet power factor might read as 0.9 but instead it is actually lower to 0.6. As a result, active PFC is developed to overcome the above circumstances.

4.2.1 Basic converter topology switch mode PFC

The following are six types of single-phase switching converter-based active power factor correction circuits: Buck, boost, buck-boost, flyback, cuk and sepic.

23

Figure 4-2: Converter types of PFC (a) Buck, (b) Boost, (c) Buck-Boost, (d) Flyback, (e) Cuk and (f) Sepic

The buck converter type circuit in figure 4-2(a) able to take in discontinuous current and supply continuous current. Despite it can supply lower voltage from the input voltage, it cannot convert a higher voltage when needed; harmonic current distortion would occur if input voltage is lower than certain range, plus the input current intake is discontinuous, thus it does not suit to AC/DC converting system. As for the boost converter circuit in figure 4-2 (b), the working principle is just the opposite of buck converter PFC circuit. The intake current is continuous while the output is discontinuous. Since the input voltage can directly control the switching, it is practically able to obtain near unity power factor. Of course, it can only produce constantly high 24

voltage output. This type of PFC converter is the most popular topology used in switch mode power factor collection circuit.

Next is the buck-boost converter topology in figure 4-2 (c). This type of converter allows stepping up or down voltage input, the polarity is opposite compare with the output voltage. Unfortunately the current supply to the circuit is discontinuous and peak current tend to bypass switching component, thus create harmonic, a harmonic filter is needed. The fly-back type isolates both input and output terminal and the circuit operation works under discreet current manner to control the switching hence normally when used for system that aim for higher power factor and low harmonic distortion would tend to install filters to increase switching speed, yet may reduce the overall efficiency and require additional EMI filter. This type of switch mode PFC is suitable for high voltage but low power system, which generally used for assisting high power converter.

As shown in figure 4-2 (e), the circuit structure of cuk topology pretty much the same behaviour as buck-boost topology, only lesser components. The sepic is the simplified version of buck-boost with two switching control and continuous input current that able to correct power factor to near unity. Each of these six types of converters PFC circuits has their own advantages and disadvantages, taking concern of discontinuous conduction mode (DCM), the distinguish power factor correction performance are outlined in table 4-1.

25

Basic Converters Buck

Input current waveform

Effect of DCM power factor correction

Less effective

Boost Good

Buck-Boost Best

Fly-back Best

Cuk and Sepic Less effective

Table 4-1: Converter base switch-mode PFC circuits attributes

26

4.2.2 Dither, Half-Bridge and Full-Bridge type PFC circuits

Figure 4-3: Dual and more switching mode PFC circuits (a) Dither circuit, (b) half-bridge circuit, and (c) full-bridge circuit.

The converter based switch mode PFC in section 4.2.1 can only allow one way flow and low power system. This section will introduce three types of bidirectional control switch mode PFC circuits, there are dither, half-bridge and full bridge circuits.

The dither topology shown in figure 4-3 (a) uses two switches to perform switching operation, where S1 and D1 take charge in correcting positive half cycle of waveform, while S2 and D2 working on the negative portion. Such circuit commonly placed before

27

an electronic circuit for power factor improvement. The only problem exists in this circuit is when voltage crossing zero, harmonic appears as the voltage difference between the switching are too small thus results the current waveform cannot maintain perfect sine wave at that particular portion.

The half-bridge circuit in figure 4-3 (b) also has two control switches with two capacitors. Similar with the dither topology, S1 and D1 perform correction at the positive half cycle while S2 and D2 responsible for the negative half. Due to this circuit has only one semiconductor component, the amount of power lost is relatively small, plus it has two supportive capacitors so it is very suitable for supplying high voltage and bidirectional source design.

As for the full-bridge circuit in figure 4-3 (c), there are altogether four control switches that allows complete control of the waveform with the same working principle as the previous two circuits. S2, S3 working as D1, D4 for positive half cycle, and S1, S4 as D2, D3 for negative half cycle. Since the full-bridge topology constructs with extra two control switches hence it is naturally cost higher and complicated to build one but in return, its ability to reduce total harmonic distortion down to the lowest extend and no distorted current appears at zero crossing like what happen in the dither topology. This is because in full-bridge topology has wider potential difference at zero-crossing hence the current able to catch up with the proper sine wave shaping.

A comparison summary of the nine switch-modes is displayed in table 4-2.

28

Converter Type Single switch mode

Double switches mode

Power can be transferred bidirectional however Capacitive Voltage might appear unstable. 2. Suitable for medium and low power supply system Four switching Full-bridge 1. Complicated, high cost mode 2. Dual direction transfer 3. Typically suits for high power transmission. Table 4-2: Summary of nine converters PFC circuits general characteristics.

Circuit Structures Buck Boost Buck-boost Fly-back Cuk Sepic Dither boost Half-bridge

1. 2. 3.

Characteristic Easy control Current flow only one way Only suitable with low power system

1.

4.2.3 PFC control in switch-mode converter topology

Though out the basic analysis of power converter topology type of PFC, it is well understood that the converter circuit such as boost converter, which able to perform conversion upon continuous current, has less electromagnetic interference, voltage control switching so that waveform able to maintain according to the original sinusoidal waveform, hence its power factor manage to reach near unity. Typically boost converter type PFC is quite famous with its simple design construction and far superior in correcting power factor for small voltage. Therefore using boost converter topology as base for explanation for the type of PFC control undertaking in general power converter based PFC circuits.

The main target to carry out power factor correction is divided into continuous conduction mode (CCM) and discontinuous conduction mode (DCM). If a design able to control both modes simultaneously, the efficiency might boost to certain extreme. However DCM is not commonly applied to many systems and meanwhile CCM has the

29

following benefits that determine its superiority compared to DCM, which thus DCM is normally omitted when designing one:

1. Able to obtain higher power factor value and lower EMI. 2. Able to use smaller output capacitor and high power density. 3. Also able to be used in high power system.

30

Chapter 5.0: System Design and Structure

5.1 Main equipment Description

Programmable Interface Circuit chip, short form named PIC chip; it is the Microchip Technologies series of micro controller. In other word, PIC is a type inexpensive single-chip computer that confines integrated circuit within it. Basically, it looks like a standard personal computer, which contains a CPU (central processing unit), RAM (Random-access memory), ROM (Read-only memory), I/O (input/output) lines, serial and parallel ports, timer, internal oscillator, and even built-in peripherals such as A/D (analogue-to-digital) and D/A (Digital-to-analogue) converters, sample/holder (S/H); more advanced features can be found in the latest series of PIC chip. The PIC used in this project is PIC16F777, which contains comparator function.

Such chip is programmed via a PIC programmer board (K8048) interfaces with personal computer using MikroC programmer and WinPIC programmer both freeware. The MikroC programming software is a programming software recognized by Microchip Cooperate.

31

Figure 5-2: K8048 Programmer Board

5.2 Circuit Designs

The design aims to monitor phase angle continuously and in the event of phase angle deviation, a correction action is initialized to compensate for this difference by continuous changing variable capacitors value via switching process. The overall system requires the only one PIC chip, few power electronic components and a bank of capacitors. Figure 5-2 shows the hardware block diagram layout of the overall system.

32

V I

Sensors

ZeroCrossing Detector

Determine phase angle and command proper action for correction

Main Computation Procedure

ADC S/H system

Switching Drivers

Capacitor Bank

Power Factor improved

PIC16F777 Chip Figure 5-2: Overview of design system

5.2.1 Sensors
The alternative voltage and current signals are both sensed and scared down using sensors, while the current is converted into an equivalent voltage representation. The sensing devices used to detect the voltage signal are a LV 25-P and LA 55-P. LV 25-P is a type of voltage transducer that able to read both DC and AC signal by converting the captured signal into smaller scale with ratio of 2500:1000; while LA 55-P is a current transducer that scares down input signal with ratio of 1:1000. These two devices can only be used if 12V15V is supplied. The devices appearances are displayed in figure 5-3.

It is essential to take caution that PIC chip can only take in certain range of input voltage, either the range of 0 to 5V with current limiting to 20mA, or higher range of voltage reading with condition that current limited within range of micro () unit. In other word, the total power dissipated within the PIC chip must not exceed 1W. The power dissipation is calculated using the following formula.

33

Pdiss = VDD (I DD I OH ) + [(V DD VOH ) I OH ] + (VOL I OL )

Figure 5-3: Voltage and Current Sensors

5.2.2 Zero crossing detector

The sensed signals transfer into zero-crossing detecting procedure. Originally, zero crossing can be detected using a specific design circuit; a simple zero-crossing detector circuit sample is shown in figure 5-4. However such design cannot apply when input voltage is too low, the output pulses tend to be distorted; a simulated result shows in figure 5-5 and figure 5-6 that describe the drawback of this circuit. This is merely simulation, the actual output also being tested and discovered that the output waveform was even distorted.

Figure 5-4: Typical sample of zero-crossing detector circuit

34

When input voltage = 110V.

Figure 5-5: Output pulses when input AC supply voltage high enough

When input voltage = 5V

Figure 5-6: Output pulses when AC supply voltage is low

35

Figure 5-7: PIC chip interface zero-crossing detector

The approached were constructed into actual circuit in figure B-4 of appendix B and proven the circuit are relatively hard to work fine practically. Such problem can be solved directly by inserting the input voltage and current signal into the PIC chip with proper component used to prevent damage to the microchip.

It is mentioned that as far as PIC chip is within 1W power dissipation, high alternating input voltage are acceptable by the chip input pins. For that, a high external resistor must be placed before the pin in order to ensure very low current supply into it. A typical input AC voltage, 50 Hz, sine wave will definitely cross from 0 to 2V; therefore a threshold around 1V will allow zero-crossing detection accuracy around 32s. The external resistor, say 5M with 110V applied to the pin will limit the current to 38A, such limited current is definitely within the safety margin of the PIC chip requirement. Further more, in order to make sure the chips safety, a diode is connected between the pin and the resistor to clip out negative portion of the sinusoidal AC input, this is because most of PIC chip pins can only accept input voltage of -0.3V to (VDD + 0.3V) with respect to VSS.

36

Figure 5-8: Zero-crossing detecting waveform using PIC interface (a) Input AC signal; (b) Input AC signal across diode; (c) Extract digital square wave input signal with comparator then invert it; (d) Using interrupt to capture the very moment when signal rise.

The above was external installation of the zero-crossing detecting process, the internal working process of the chip is mainly control using software programmed into it. By using an existing unique function in PIC16F777 the comparator; it is a module that able to perform threshold comparison by either using certain fraction the on-chip voltage VDD or supply an external voltage as voltage reference, hence a square wave output is then generated according to the reference threshold voltage. When a rise signal

37

is detected, the software creates an interrupt and directly store into the RAM for later phase angle calculation, the capture of interrupt work like a pulse generated at the very moment when the waveform cross below the threshold voltage. Even though the overall process will certainly have some delay within the system however it will be small and would not affect much upon the actual reading. An expecting zero-crossing signal detecting output is shown in figure 5-8.

5.2.3 ADC and shunt capacitor bank

Conversion of analogue to digital is done within the PIC chip. Such process is done automatically as PIC chip can only produce digital outputs; the intelligence of the microchip provides a cinch to PIC programming user, who wants to deliver digital pulses at output pin. The main task for this section is proper allocation of the output signal to trigger sufficient shunt capacitors to compensate with leading VAR so that to improve the connected power system with loads. The overall working principle is discussed in the flow chart in section 5.3.3

5.3 Design Flow Chart

The designed programs that operate internally in PIC chip are presenting in flow chart presentation with detail explanations to gain in depth view for this project.

5.3.1 Zero-crossing Detecting Module

As reference in figure 5-8, it was the expecting output pulses of what the following module should get. Actually the input signal can be rectified into full wave rectified output using a four diodes bridge circuit but in order to simplify the work for capturing

38

signals between voltage and current since there is possibility that voltage half cycle might cross zero point before current signal does, it is preferable to block the negative portion of the sinusoidal signals.

Figure 5-9: Flow chart for zero crossing detector

39

The self-designed zero crossing detector gives priority to detect voltage signal with a slight delay at beginning so that to ensure the first signal capture would have higher possibility to detect at crossing zero position instead of somewhere in the middle of rising edge. With comparator function in the PIC16F777 chip, setting a threshold voltage of approximate 0.4V using the following equation to extract certain ratio of VDD as reference voltage as a representation of the threshold voltage.

CVR VDD = Cvef 24

Where,

CVR = Comparator reference supply voltage Cref = Comparator reference voltage (threshold voltage)

Taking CVR = 0010, which equivalent to 2 of decimal as CVR. (2/24) 5 = 0.41677 V. Once the threshold voltage is set, the comparator will continuously trace input voltage and current signals on and on, two trains of pulses with respect to timer are stored into RAM stacks. Whenever a pulse were created and stored, a flag would trigger so that to keep track with general clock timer. The voltage flag will continue shooting until the current flag is detected and stored into RAM as well, then both flags would reset and begin another round of detection.

40

5.3.2 Phase Angle Computation Module

Figure 5-10: Flow chart for phase angle computation module

After the process of locating the zero crossing positions, determine the phase angle difference under pure sinusoidal current is now possible. Figure 5-10 is the flow chart diagram of the phase angle computation.

41

The zero-crossing module sends stored signals into this function module, using general clock as the main division of two timers. The flags captured in previous mode stored up records of flag running in term of times. Prior setting of frequency for this system is 8MHz. So the total time interval is

T=

1 1 = = 0.125ms f 8 10 6

Say time difference recorded is 0.025ms, hence the phase angle difference would be

Time difference = current time voltage time = 0.005 10 6 Time elapsed = 0.005 10 6 = 0.02 0.125 10 6

Phase angle = 0.04 360 = 14.4 (lagging)

Hence, the power factor, pf = cos = cos(14.1) = 0.9686 = 96.86%

Since most system are lagging in general, thus if current time found to be lower than voltage, it will reset the system and start all over again.

42

5.3.3 Capacitor bank switching control module

Figure 5-11: Flow chart for Capacitor bank control module

As the power factor has been determine, applied with appropriate mathematic calculation, the amount of capacitor required to aim for higher power factor output can

43

be found. The mathematic calculating process shall be discussed in the next chapter with actual reading

The capacitor bank control module is used to decide how many stages of capacitors should be activated. For a mathematic computed capacitor value, the system will start comparing that value with the bank stage by stage starting from the lower and smallest capacitor value. The first detect is if the system is turned on or not, if nothing connected to the PFC system, this module will order all capacitors to be disconnected and discharged via the resistors installed in the circuit. Such process done by using the max capacitor value in the bank deduct the wanted capacitor value, the system will turn all drivers off if found that the capacitor bank value is the same of the leftover capacitor value after deduction, then it is confirmed there are no inductive reactance occurs in the power system or system is remained off.

The way to find out how much capacitor is actually needed for the power system through the working process of this module, is deduct starting capacitor stages if the capacitor value is lower than the maximum amount; such process continue until the required capacitive value of the bank match or close to the wanting value as computed. An extra feature is to detect how many stage are actually installed into the system, the remaining available capacitors will continue perform the same process with extra detection for remaining capacitor in the bank. Note that the minimum installation for this module is at least three stages.

44

Chapter 6.0: Implementation & Results

6.1 Implementation procedures and target results

The idea is to connect to two types of power system single-phase and three-phase, with existence of inductive reactance one at a time in order to test how accurate and efficient the designed circuit ability to correct the power factor. The level of improvement and faults would be recorded. For an ideal expectation, the designed circuit should be able to detect the initial power factor correctly with near zero uncertainty for each type of assigned power system, which here used a single-phase power generator with inductor loads and an AC motor. The first testing stage was tested with fixed inputs.

The next step was to determine the system sensitivity through generate various kind of inputs. For both single-phase and three-phases power systems, each was tuned up and down of its input voltage value with reasonable range or varied the loads simultaneously within a period of time so that to test how sensitive the designed circuit capable to detect the power factor of the system. With each two major experiment, the final goal was automatic correcting power factor after extracted power factor and other necessary parameters information; the improved power factor value would be jobbed down; since collecting power factor involves capacitor switching and the how much power factor being improved depends on the amount of capacitor in use hence precalculation is needed for testing purposes.

45

Input voltage signal

(1)

Reference voltage

(2)

Signal output to oscilloscope

(3)

Figure 6-1: Test setting for zero-crossing detector

6.2 Implemented results and discussions

The system design implementation and testing were being divided into three major parts: Test on zero-crossing detector, test on fixed input system and finally test on a various inputs system. Since the power factor reading test is different for both singlephase and three-phase, thus individual testing was carried out in two different sections. Follow by then is correcting the power factor and this process also distributed in the last two sub-chapters.

6.2.1 Test on zero-crossing detector module

Figure 6-1 shows the structural configuration to run a test upon the zero-crossing detector module. Using a model, INSTEK GFG-8020H signal generator to supply a frequency of 50 Hz and 5V into the PIC microchip at PIN number 2 then set an external reference voltage using power supply to provides constant DC voltage into PIN number 5, observed the output signal via oscilloscope (model TDS 1012). It should be cautioned not to over tunning the input voltage more that 5V.

46

All groundings were connected together with VSS. Meanwhile, the oscilloscope first channel probe were attached to the input voltage signal port (1) before diode and the channel two attached to port (1) after diode to find out if the sinusoidal signal were really clipped the negative portions, then attached to port (3) to monitor the output waveforms.

Figure 6-2 shows the testing results observed through the oscilloscope. In figure 6-2 (a), the channel 1 displayed a complete sinusoidal signal while channel 2 was outcome of input voltage after bypassed the diode before entering into pin port (1), the diode clipped the negative portion of the sine waveform so that to prevent PIC take in excessive negative voltage; at the same time, it itself drained some voltage hence channel 2 waveform was slightly lower. Make sure a shunt resistor of any value must be connected after the diode and link to ground, this will prevent harmonic appears.

Before obtained the output waveform in figure 6-2 (b), it should be aware that pin 6, which is RA4 is an open drain output that pull down output signal, thus a pull up resistor is needed by connecting it to VDD then able come out with desired output. The DC power supply was connected to port (2) and supplied a reference voltage as threshold voltage, which is lower than 5V. The reference voltage supplied into port (2) were 3.74V hence the bandwidth of the square wave rising pulse train was very small. In order to locate precise zero-crossing point, the threshold voltage were reduced until reaching approximately 0.524 V before null, the rising edges and falling edges were almost perfectly drop on every zero points, this are clearly displayed in figure 6-2 (c).

47

Output waveform in figure 6-2 (c) was actually sufficient enough to apply into the program coding to run the rest of the experiments. However this may not be a satisfied result compare with the simulated result in figure 5-5, so a slight modification in the programming code was done using the capture module setting as follow to capture every finite moment of rising edges and falling edges, a train of perfect zero-crossing pulses are demonstrated via oscilloscope as shown in figure 6-2 (d).

PIE1 = 0b00000101; PIE2 = 0b01000001; CCP1CON = 0b00000101; CCP2CON = 0b00000101;

// Enable CCP1 & TMR1 overflow interrupt // Enable CCP2 // Detect every rising edge for voltage // Detect every rising edge for current

Figure 6-3 displays the actual circuit wiring while running the zero-crossing detecting test after the results demonstrated.

Output voltage

Input voltage

Figure 6-2 (a): Voltage output after diode at the input port.

48

VREF = 3.74V

Output voltage

Figure 6.2 (b): Output voltage with VREF = 3.74V

Output voltage VREF = 0.524V

Figure 6.2 (c): Output voltage with VREF = 0.524V

49

VREF = 0.524V

Output voltage pulse

Figure 6-2 (d): Output voltage after apply capture mode with VREF = 0.5247

(b) (d)

(a)

Figure 6-3: Actual circuit wiring, the labeling determine the position of results

50

6.2.2 Test on phase angle detection

This was attempted using an existing induction motor based device home table fan. The table fan was connected with an oscilloscope for monitoring the waveforms, a sensors box (both current transducer and voltage transducer are built inside), and DC power supply to provide threshold voltage to the PIC. A typical picture is shown in figure B-6 of appendix B.

The power factor measured for the table fan were quite high, around 0.99234, even increased its load to the level 3 of its fan rotation. Hence calibration was needed to obtain a clear view upon the phase changes. During the testing process, the designed sensor used to test was having a major problem to determine the output. This was because the converting ratio for the current sensor is 1:1000; while the current exist in the table were only 0.03A, which after converted would be 30A. Bypassing with some resistors and converted into voltage value was not even exceed 0.04 V, such voltage level would definitely cannot even passed through the diode, which has voltage drop of 0.7V.

The solution was using an operational amplifier - model UA741CP to boost up the input so that it can be view on screen. A clear picture is shown in figure 6-4 of how the circuit were connected. The operational amplifier not only serves to amplify the current input but also can work as a system calibrator. This was a great help for future developing of the system as the clearly shown the delay occurred in the designed system hence proper calibration can be done to make the system more perfect.

51

Diode Current input

Op-Amp

LEDs correspond to fan buttons

Voltage input

Voltage (left) and current (right) outputs

Figure 6-4: Circuit constructed to test phase angle.

The test was simple after solving the problem of low input reading, simply pressed the button from 0 ~ 3 to observe the changes in phase difference. The LEDs were used to run a prior test for the next section. The leftmost LED was just used to find out if the system was running. The red LED was with highest PF button 1 then follow by button 2 and button 3; the oscilloscope also presented the results as displayed in figure 6-5(a)(d). The reason was to run experiment that phase angle can direct affecting the output without concerning the reactive power. The digital time step differences for PIC to identify the button were calculated using the following equation:

time step =

measured phase difference in time 500ns

(6 1)

52

Voltage output Current output = 0V

Figure 6-5 (a): When no button (or button 0) was pressed

Voltage output

Current output

Figure 6-5 (b) When button number 1 was pressed

53

Voltage output

Current output

Figure 6-5 (c): When button 2 was pressed.

Voltage output

Current output

Figure 6-5 (d): When button 3 was pressed.

54

Single-phase power supply unit + Inductive loads

PIC16F777 phase angle measuring

PIC16F777 pf c control process Lab measuring tools

Capacitor bank

Represents comparison and checking readings

Figure 6-4: Block diagram of power factor corretion testing process

6.2.3 Test on fixed input AC power system

6.2.3.1 Single-phase system test procedure

The single-phase fixed input AC power system test is by using an AC voltage regulator supply unit and applies some loads onto it resistors and inductor. The frequency of the supply unit is 50Hz, which directly extracts from normal electrical socket. A typical testing module was built according to the block diagram as shown in figure 6-4, with supportive measuring tools to check and to verify the testing outputs with respect to the PIC chip. The single-phase voltage generator can supply up to 240VAC, but it is a type that can only be regulated manually by twisting the knob, where percentage values are labelled on it. The same device will then be used for various inputs test as well.

The first test was supplying a fixed input voltage around 100VAC with different loads. The main parameters that required determining are: measured phase angles, actual power factor values, corrected power factor values, number of capacitors triggered.

55

Record and tabulate the retrieved parameters into tables and plotting graph to view the system efficiency.

In this section of testing was with the program to execute power factor correction process. Unlike the second phase program, the first phase using timer1 as register to store temporary data. There is a critical situation must a PIC programmer be aware of, although timer1 is being used as a temporary storage register but it is still a timer that will continuously running increment until it reaches its limit and overflow, consequently reset. If programmer ignore this, there are chances that the program being restarted before finish. Some calculation is needed to avoid the above consequences.

The settling frequency in the PIC oscillator = 8MHz Only quarter will be used, thus FOSC = 8 106 = 2 106 = 2 MHz 4

For timer1 is a 16-bits register, so 216 = 65536 Hence total available time for timer1 to run 1 cycle is 65536 = 0.035768 sec = 32.768ms 2 106

So long the program can accomplish its job that required timer1 before it reset, else the result retrieved would definitely wrong.

6.2.3.2 Three-phase system test procedure

A three-phase induction motor through an electrical test bed would be a suitable testing apparatus. It is assumed that unbalance condition is very minute hence the phase angle differences are technically the same in each line, hence the PFC system would only read 56

a single line current and a line voltage out of the three lines then work out appropriate calculation to perform suitable power factor correction process. Such assumption were made because the modules used within microchip, as well as the programmed code were only capable to take in two inputs for zero-crossing detection and comparison, hence the parameters to be tested will be the same as single phase, only that the calculation would be different than the single phase calculation.

6.2.3.3 Overall tested result for fixed input

Although calibration was made during testing with phase angle detection in section 6.2.2 in order to ensure the system run smooth in the rest of testing, however such attempt still unable to guarantee a nice output; calibration is still needed. Figure B-7 of appendix B was photo taken for running the test of this section.

Due to insufficient of time proceeding detail testing, the testing stage was done through observation of LED. The first attempt was supplying 101 VAC to the load of 210 resistor from the resistive loading bank and 0.67H from the inductive loading bank, series connection. The calculation below determines the power factor value:

Vin = 1000 Given R = 210 L = 0.67 H

ZTotal = R + jX L = 210 + j (2 50 0.67 ) = 210 + j 210.49

I=

V 1010 1000 = = = 0.3397 45.06 ZT 210 + j 210.49 297.3345.06

PF = cos 45.06 = 0.7063 = 70.63%

57

Supposing the amount of LED lit should be five pieces but the instead it was only three. Adjustment were made by increasing the threshold of the operational amplifier, also slight tuning at the PIC threshold voltage. Finally, it was managed to secure up to five LED but the threshold for operational amplifier seem to be at its limit because if further increase will lose the signal; hence it was discovered that LED number five kept on blinking with approximately 4 to 6 seconds each.

A second trial was using two parallel resistors and 4 parallel inductors connected in series with the source.

R = 210 // 210 = 105 L = j 210.49 // j 210.49 // j 210.49 // j 210.49 = j 52.6225 ZT = R + L = 105 + j 52.6225 I= V 101 = = 0.8599 26.618 ZT 105 + j 52.6225

PF = cos 26.618 = 0.894 = 89.40%

With calibration done, two LED were lit but the third were slightly blinking as 0.89 PF is almost 0.90. As a result, the system running considered quite satisfied; it was regret that unable to construct the capacitor switching. The idea was suppose to drive a MOSFET directly from the output pins then into the relay to draw connection with the capacitor banks link with the electric bus.

Since the same application can be assumed applicable in three-phase system wyesystem, hence with the least amount of time in hand, it was suspect it can work quite well the three-phase system as well.

58

6.2.4 Test on various inputs

This test main concern is the sensitivity of the designed system. The testing process is to test how fast the system can react when power supply behaves like an emergency power supply. In other word, the power supply would vary its input in ascending order or descending order or triggering up and down; certainly this would be done manually. This part was task for the second phase of the programmed code and testing with the same appliances used in section 6.2.2.

Unfortunately the desired output cannot be implementing as PIC chip cannot cope with the changes made. Whenever there were changes made, the power factor reading lost somewhere, it was suspected that few looping functions within the code were messed when different voltage inputs supplied. Due to limitation of time, amendment seems impossible. The second reason, PIC16F777 has no EEPROM to keep history on track; the timer1 in section 6.2.2 can only perform counting one at a time, if an unpredicted change appeared just in the middle while detecting phase angle is processing; it will get a wrong reading or become never ending loop, as a result system completely crashed. With EEPROM, data storage can perform precise comparison and by averaging the past results to get power factor to a nearer and reasonable range if system is unstable.

6.3 Review of goals

The tests on fixed voltage input with different loads were considered 60% success provided the condition that pre-calculation of desired power factor value and supplies enough shunt capacitors of same value. So far the system only designed of capable to run switching on maximum 8 stages of capacitors.

59

The various voltage inputs test was not able to accomplish its task however it can be improved with PIC chip that have EEPROM. If necessary, an external crystal can be used to rise the clocking frequency thus able to perform a lot of arithmetic calculation, as well as avoid bus congestion.

60

Chapter 7.0: Future Direction and Conclusion

The testing process did not run test on power converter based systems or synchronous motor due to required huge amount of expense may need to further enhance the system to such feature, financial is a critical issue upon further enhancement. Besides, as discuss in chapter 3 and chapter 4, systems that contain serious harmonic current or ill non-sinusoidal current would mostly exist in power system with a lot of active elements.

The final result was not quite the desired output but the idea of making one workable simple PIC-based power factor correction with the developed system is absolutely possible.

7.1 Future Direction

In chapter 4 mentioned about power factor correction can be constructed with many and better approach; as this project did not focus on power system with distorted current or non-linear waveform system, it is a good idea to further study and getting in depth knowledge to achieve a better type of power factor corrector using the PIC. The idea of using converter in for the active power factor circuit was because it can regenerate the current waveform by amplifier and smoothen it through converter system; such action with detail understand might can be done with software calibration as well as using PIC chip to perform suitable control along the circuit. In the present technology, PIC mostly used as switching control for mainly switched-mode distribution power system,

61

however the increment of green energy had turn the focal point towards renewable energy and until present era, renewable energy still facing serious problem with poor power quality, which low power factor is one of the main reasons.

As a result, many firms spent a lot of investment to solve the problem. PIC chip is a good example of financial solution as one single chip can nearly do everything plus it only consume very low voltage supply.

62

References
H. Saadat, Power System Analysis, Mc Graw Hill, US, 1999. TVPPA group, Distribution Design Guidelines, Chapter 8 Capacitors, pp 256-295, Booth & Associates Inc., Alexander Publications. FAQ: What is power factor 2006. Retrieved 04 July 2006, from http://www.endpcnoise.com/cgi-bin/e/faqpfc.html J. M. Bourgeois, Circuit for power factor correction with regards to mains filtering, STMicroelectronics, Italy. Retrieved August 23rd, 2006 from http://www.st.com/stonline/products/literature/an/3727.htm M. Chin 2005, Power Fundamentals & Recommendations, pp 5-7, SPCR. Retrieved September 1st, 2006 from http://www.silentpcreview.com/article28-page5.html K8048 Velleman Board Datasheet. Retrieved March 10th, 2006, from http://dev.kewl.org/k8048/k8048/ Power Factor, LM Photonics Ltd. Retrieved September 8th, 2006 from http://www.lmphotonics.com/pwrfact.htm Lesson in Electric Circuits Volume 11, Power Factor , Chapter 11. Retrieved May 18th, 2006 from http://www.ibiblio.org/obp/electricCircuits/AC/AC_11.html AN220 Watt-Hour Meter using PIC16C923 and CS5460. Retrieved June 5th, 2006 from http://www.microchip.com/stellent/idcplg?IdcService=SS_GET_PAGE&nodeId =1469&filter1=function AN939 Designing Energy Meter with PIC16F873A Retrieved July 25th, 2006 from http://www.microchip.com/stellent/idcplg?IdcService=SS_GET_PAGE&nodeId =1469&filter1=function AN521 Interfacing to AC Power lines. Retrieved August 27th, 2006 from http://www.microchip.com/stellent/idcplg?IdcService=SS_GET_PAGE&nodeId =1469&filter1=function

63

Appendix A
Program Code
unsigned int Iph; int ph_diff; unsigned short x1, x2;

void main () { OSCCON = 0b01110000; // Use 8MHz

ADCON1 &= 0b11110000; ADCON1 |= 0b00001011;

// Clear PCFG0~3 Pins // RA0-RA3 analogue, RA4-RA7 digitals

T1CON = 0b00000001;

// Simply enable TMR1, Prescale 1:1

TRISA = 0b11001111; TRISD = 0b00000000; TRISB = 0b00000000;

// set RA4 & RA5 as output, the rest are input // Set portD as output for ensure chip working // set portB as output for 2ndary comparator output

// --- zero crossing detector --- // CMCON = 0b00110101; // select mode 101, invert all input

// --- Power factor computation -- //

64

x1 = 0; x2 = 0;

if (CMCON.C1OUT == 1 && x1 == 0) { TMR1L = 0; TMR1H = 0; x1 = 1; x2 = 1; } // reset TMR1

if (CMCON.C2OUT == 1 && x2 == 1) { Iph = TMR1L; Iph = TMR1H << 8; ph_diff = Iph - 0x0000; x2 = 0; } // compute phase difference

if (CMCON.C1OUT == 0 && x2 = 0) { x1 = 0 }

//restart all

65

// --- Capacitors Stage Triggering --- //

// phase different calculation with respect to time // time phase difference = [(angle / 180 deg) / 50 freq ] * 2.0e6

if (ph_diff <= 4043) PORTB.F1 = 1;

// pf >= 0.95 // LED RB1 lit to determine no need correction

else if (ph_diff >= 4043 && ph_diff <= 5743) PORTB.F2 = 1;

// 0.95 > pf > 0.90

// stage 1 capacitor trigger

else if (ph_diff >= 5743 && ph_diff <= 7064) { PORTB.F2 = 1; PORTB.F3 = 1; } else if (ph_diff >= 7064 && ph_diff <= 8193) { PORTB.F2 = 1; PORTB.F3 = 1; PORTB.F4 = 1; } else if (ph_diff >= 8193 && ph_diff <= 9202) { PORTB.F2 = 1;

// 0.90 > pf > 0.85

// stage 1 capacitor trigger // stage 2 capacitor trigger

// 0.85 > pf > 0.80

// stage 1 capacitor trigger // stage 2 capacitor trigger // stage 3 capacitor trigger

// 0.80 > pf > 0.75

// stage 1 capacitor trigger

66

PORTB.F3 = 1; PORTB.F4 = 1; PORTB.F5 = 1; }

// stage 2 capacitor trigger // stage 3 capacitor trigger // stage 4 capacitor trigger

else if (ph_diff >= 9202 && ph_diff <= 11806) // 0.75 > pf > 0.60 { PORTB.F2 = 1; PORTB.F3 = 1; PORTB.F4 = 1; PORTB.F5 = 1; PORTB.F6 = 1; } else if (ph_diff >= 11806) // pf < 0.6 { PORTB.F2 = 1; PORTB.F3 = 1; PORTB.F4 = 1; PORTB.F5 = 1; PORTB.F6 = 1; PORTB.F7 = 1; } else PORTD.F1 = 1; // indicate pf exceed below 0.6 // stage 1 capacitor trigger // stage 2 capacitor trigger // stage 3 capacitor trigger // stage 4 capacitor trigger // stage 5 capacitor trigger // stage 6 capacitor trigger // stage 1 capacitor trigger // stage 2 capacitor trigger // stage 3 capacitor trigger // stage 4 capacitor trigger // stage 5 capacitor trigger

while (1) {

67

PORTD.F0 = ~PORTD.F0; delay_ms(1000); */ } }

// Ensure MCU working

68

Appendix B

PIC16F777 microchip

Figure B-1: PIC16F777 Microcontroller chip

69

MikroC version 6.0 program overview

Figure B-2: MikroC microchip programming software

70

WinPIC software (DL4YHF's PIC Programmer for Windows)

Figure B-3: Win PIC programmer microchip interface software

71

Test on Zero-crossing Circuit (Built circuit and result)

Figure B-4: Zero-crossing circuit hardware structure

Figure B-5: Output waveforms of above circuit

72

Environment of phase angle testing progress

Figure B-6: Picture taken when testing phase angle using induction motor (table fan)

Environment of single phase power factor testing progress

PIC circuit

Sensors

Single-phase voltage regulator

Figure B-7: Testing for single phase variable loads

73

Appendix C
Sample of actual PFC 3-phase connection diagram

Figure C-1: 3-Phase system cable connection (TCS Perunding Ltd. Co.)

74